Nitron Condense Nitron Condense 28 (H-TR)

Transcription

1 Installation and maintenance instructions Nitron Condense Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) TR

2 Contents Contents Safety Action-related warnings Intended use General safety information Safety information pertaining to the air/flue gas installation Regulations (directives, laws, standards) Notes on the documentation Observing other applicable documents Storing documents Applicability of the instructions Product description Design Overview of the operator control elements Information on the identification plate Symbols on the product CE label TSE symbols Installation Unpacking the product Checking the scope of delivery Dimensions Minimum clearances Clearance from combustible components Using the installation template Wall-mounting the product Installing/removing the front casing and the chamber cover Removing/installing the side section... 5 Installation Installation requirements Installing the gas connection and heating flow/return Installing the hot and cold water connection Filling the siphon and connecting the condensate discharge pipe Connecting the discharge pipe to the expansion relief valve on the product Flue gas installation Electrical installation Connecting additional components Operation Operating concept Calling up the installer level Start-up Initial start-up Switching on the product Checking and treating the heating water/filling and supplementary water Preventing low water pressure Filling and purging the heating installation Filling and purging the hot water circuit Setting the heating flow temperature Setting the hot water temperature Checking and adjusting the gas ratio setting Checking function and leak-tightness Adapting the unit to the heating installation Calling up/setting parameters Remaining feed head of the pump Setting the pump output Handing the product over to the operator Troubleshooting Rectifying faults Calling up/clearing the fault memory Preparing the repair work Completing repair work Observing inspection and maintenance intervals Procuring spare parts Preparing the cleaning work Completing cleaning work Draining the product Checking the admission pressure of the expansion vessel Completing inspection and maintenance work Decommissioning Temporarily decommissioning the product Decommissioning the product Recycling and disposal Customer service Appendix A Installer level Overview B Inspection and maintenance work Overview C Fault messages Overview D Troubleshooting Overview E Connection diagram F Technical data G Air/flue gas installation G. Minimum clearances for the air/flue gas installation G.2 Length of the air/flue gas installation, dia. 60/00 mm G.3 Length of the air/flue gas installation, dia. 80/80 mm G.4 Length of the air/flue gas installation, dia. 80/25 mm Index Installation and maintenance instructions _00

3 Safety Safety. Action-related warnings Classification of action-related warnings The action-related warnings are classified in accordance with the severity of the possible danger using the following warning signs and signal words: Warning symbols and signal words Danger! Imminent danger to life or risk of severe personal injury Danger! Risk of death from electric shock Warning. Risk of minor personal injury Caution. Risk of material or environmental damage.2 Intended use There is a risk of injury or death to the user or others, or of damage to the product and other property in the event of improper use or use for which it is not intended. The product is intended as a heat generator in closed central heating installations and for central hot water generation. When used in solar systems, the product is only suitable for hot water generation. The product is mounted on a wall such that it is possible to route air supply pipes and flue gas pipes. Suitable installation locations include basements, storage rooms, multi-purpose rooms or living rooms. Fresh air must be supplied at a sufficient rate. The products referred to in these instructions must only be installed and operated in conjunction with the flue pipe accessories listed in other applicable documents. Exceptions: For C63 and B23P installation types, follow the specifications in these instructions. Intended use includes the following: observance of accompanying operating, installation and servicing instructions for the product and any other system components installing and fitting the product in accordance with the product and system approval compliance with all inspection and maintenance conditions listed in the instructions. Intended use also covers installation in accordance with the IP class. Any other use that is not specified in these instructions, or use beyond that specified in this document shall be considered improper use. Any direct commercial or industrial use is also deemed to be improper. Caution. Improper use of any kind is prohibited..3 General safety information.3. Risk caused by inadequate qualifications Assembly and disassembly, installation, startup, maintenance, repairs and decommissioning must only be carried out by a competent person who is sufficiently qualified to observe all of the instructions that come with the product, to proceed in accordance with the current state of the art, and to comply with all applicable directives, standards, laws and other regulations..3.2 Risk of death from escaping gas What to do if you smell gas in the building: Avoid rooms that smell of gas. If possible, open doors and windows fully and ensure adequate ventilation. Do not use naked flames (e.g. lighters, matches). Do not smoke. Do not use any electrical switches, mains plugs, doorbells, telephones or other communication systems in the building. Close the emergency control valve or the main isolator. If possible, close the gas isolator cock on the product. Warn other occupants in the building by yelling or banging on doors or walls. Leave the building immediately and ensure that others do not enter the building. Alert the police and fire brigade as soon as you are outside the building _00 Installation and maintenance instructions 3

4 Safety Use a telephone outside the building to inform the emergency service department of the gas supply company..3.3 Risk of death due to blocked or leaking flue gas routes Installation errors, damage, tampering, unauthorised installation sites or similar can cause flue gas to escape and result in a risk of poisoning. What to do if you smell flue gas in the property: Open all accessible doors and windows fully to provide ventilation. Switch off the product. Check the flue gas routes in the product and the flue gas diversions..3.4 Risk of death from leaks if the product is installed below ground level! Liquid gas is accumulating at floor level. If the product is installed below ground level, liquid gas may accumulate at floor level if there are any leaks. In this case, there is a risk of explosion. Make sure that liquid gas cannot escape from the product or the gas line under any circumstance..3.5 Risk of death from escaping flue gas If you operate the product with an empty condensate siphon, flue gas may escape into the room air. In order to operate the product, ensure that the condensate siphon is always full..3.6 Risk of death due to cabinet-type casing Cabinet-type casing can give rise to dangerous situations when used on a product which is operated with an open flue. Ensure that the product is supplied with sufficient combustion air..3.7 Risk of death due to explosive and flammable materials Do not use or store explosive or flammable materials (e.g. petrol, paper, paint) in the installation room of the product..3.8 Risk of death from electric shock There is a risk of death from electric shock if you touch live components. Before commencing work on the product: Disconnect the product from the power supply by switching off all power supplies (electrical partition with a contact opening of at least 3 mm, e.g. fuse or line protection switch). Secure against being switched back on again. Wait for at least 3 minutes until the capacitors have discharged. Check that there is no voltage..3.9 Risk of death due to lack of safety devices The schematic drawings included in this document do not show all safety devices required for correct installation. Install the necessary safety devices in the system. Observe the applicable national and international laws, standards and guidelines..3.0 Risk of poisoning and burns caused by escaping hot flue gases Only operate the product if the air/flue pipe has been completely installed. With the exception of short periods for testing purposes, only operate the product when the front casing is installed and closed..3. Risk of poisoning caused by insufficient supply of combustion air Conditions: Open-flued operation Ensure that the air supply to the product's installation room is permanently unobstructed and sufficient in accordance with the relevant ventilation requirements. 4 Installation and maintenance instructions _00

5 Safety.3.2 Risk of being burned or scalded by hot components Only carry out work on these components once they have cooled down..3.3 Risk of injury during transport due to a high product weight. Make sure that the product is transported by at least two people..3.4 Risk of corrosion damage due to unsuitable combustion and room air Sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia compounds, dust or similar substances may lead to corrosion on the product and in the air/flue pipe. Ensure that the supply of combustion air is always free of fluorine, chlorine, sulphur, dust, etc. Ensure that no chemical substances are stored at the installation site. Ensure that the combustion air is not routed through chimneys which have previously been used with floor-standing oil-fired boilers, or with other boilers, which could cause soot to build up in the chimney. If you are installing the product in hairdressing salons, painter's or joiner's workshops, cleaning businesses or similar locations, choose a separate installation room in which a combustion air supply is ensured that is technically free of chemical substances..3.5 Risk of material damage caused by frost Do not install the product in rooms prone to frost..3.6 Risk of material damage caused by using an unsuitable tool Use the correct tool to tighten or loosen screw connections..4 Safety information pertaining to the air/flue gas installation.4. Risk of death from escaping flue gas Ensure that all openings in the air/flue pipe that are within the building and can be opened are always closed for start-up and during operation. Flue gas may escape from leaking pipes or damaged seals. Mineral-oil-based greases can damage the seals. When installing the flue gas installation, use only flue pipes of the same material. Do not install any damaged pipes. File off sharp burrs and chamfer the ends of the pipes before installing them, and dispose of the shavings. Never use mineral-oil-based grease for the installation. To facilitate the installation, use only water, standard commercial soft soap or, if required, the enclosed lubricant. Mortar residues, shavings, etc., in the flue gas route may restrict the outward flow of the flue gas, meaning that flue gas can escape. After installation, remove all mortar residues, shavings, etc., from the air/flue pipe..4.2 Risk of death from escaping flue gas due to negative pressure For open-flued operation, the product must not be placed in an installation site from which the air is extracted using fans and in which negative pressure is generated (ventilation systems, extractor hoods, tumble dryer ventilation). This negative pressure can cause flue gas to be sucked into the installation site from the opening through the annular gap between the flue gas pipe and the shaft. If you are operating the product with an open flue, make sure that there are no other systems/units producing negative pressure in the installation site..4.3 Risk of injury from ice formation Where air/flue pipes penetrate the roof, the water vapour contained in flue gas may pre _00 Installation and maintenance instructions 5

6 Safety cipitate as ice on the roof or the roof structures. Ensure that this ice formation does not slide from the roof..4.7 Risk of material damage caused by an adjacent channel vent.4.4 Risk of fire and damage to electronics caused by lightning H 0 If the building is equipped with a lightning protection system, incorporate the air/flue pipe into the lightning protection. If the flue gas pipe (parts of the air/flue pipe situated outside the building) contains metal materials, incorporate it into the potential equalisation system. m 3 m m.4.5 Risk of corrosion caused by sooted chimneys Chimneys that previously discharged the flue gas from oil- or solid-fuel-fired heat generators are unsuitable for supplying combustion air. Chemical deposits in the chimney may pollute the combustion air and cause corrosion in the product. Ensure that the supply of combustion air is free from corrosive materials..4.6 Moisture damage caused by incorrect installation location of the inspection elbow Conditions: Diameter: 60/00 mm; 80/80 mm; 80/25 mm An incorrect installation location leads to condensate leaking from the cover of the inspection opening and may lead to corrosion damage. Install the inspection elbow in accordance with the illustration. Extremely damp exhaust air escapes from the channel vents. This may condense in the air pipe and cause damage to the product. Observe the requirements for minimum clearances in accordance with the illustration..4.8 Risk of material damage caused by flue gases or dirt particles that have been sucked in If the opening on the air/flue gas installation is adjacent to a chimney, flue gases or dirt particles may then be sucked in. Sucked-in flue gases or dirt particles may damage the product. If the adjacent chimney feeds flue gas with an extremely high temperature or soot starts to burn, the opening to the air/flue gas installation may be damaged by the heat effect. Take suitable measures to protect the air/flue gas installation by raising the chimney, for example..5 Regulations (directives, laws, standards) Observe the national regulations, standards, guidelines and laws. 6 Installation and maintenance instructions _00

7 Notes on the documentation 2 2 Notes on the documentation 2. Observing other applicable documents You must observe all the operating and installation instructions included with the system components. 9 Electronics box 0 Pressure compensation tube Safety cut-out (SCO) 2 Ignition electrode 3 Monitoring electrode 4 Burner 5 Primary heat exchanger 6 Hood 2.2 Storing documents Pass these instructions and all other applicable documents on to the system operator. 2.3 Applicability of the instructions These instructions apply only to: Product article number Turkey Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Design of the hydraulic block Product description 3. Design Expansion relief valve 2 Pressure sensor 6 Flow rate sensor (DHW) 7 Automatic air vent 3.. Design of the product 3 Diverter valve 8 Heating pump 4 Immersion sensor 9 Gas valve 2 5 Secondary heat exchanger Overview of the operator control elements eco button 2 Heating mode button (On/Off) 3 Rotary knob (ON/OFF) 4 Heating mode button (set the temperature) 5 reset button 6 Display (operating displays) 7 Hot water handling mode button (set the temperature) Information on the identification plate The identification plate is attached to the product at the factory. Information on the identification plate Meaning Fan 2 Expansion vessel 3 Air pressure sensor 4 Flue gas temperature sensor 5 Recuperator 6 Overheating thermostat 7 Heating pump 8 Hydraulic block "CE label" section _00 Installation and maintenance instructions 7

8 4 Installation Information on the identification plate Meaning "TSE symbols" section 3.4 Symbols on the product Symbol Meaning Access to the potentiometers Read the instructions. The product is connected to 230 V mains voltage "Recycling and disposal" section Connecting to the room thermostat H-TR 24, 28 Output Type designation 3.5 CE label H TR V W Hz MPa (bar) IP Cat. (e.g. II 2H3+ ) Type (e.g. C 2 ) G20 20 mbar (2 kpa) ww/jjjj (e.g. 09/205) PMW (e.g. 8 bar (0.8 MPa)) PMS (e.g. 3 bar (0.3 MPa)) ED 92/42 P T max. Q D Type of gas (e.g. natural gas) Designated country (target market) Mains voltage Power consumption Power frequency Max. line pressure Level of protection/protection class Approved gas category Approved flue gas connections Gas group and gas connection pressure as set at the factory Date of manufacture: Week/year Permissible total overpressure during hot water generation Permissible total overpressure in heating mode Current efficiency directive fulfilled with 4* rating Nominal heat output range Max. flow temperature Heat input range Nominal hot water draw-off rate Heating mode Hot water generation Bar code with serial number, The 7th to 6th digits of the serial number form the article number The CE label shows that the products comply with the basic requirements of the applicable directives as stated on the identification plate. The declaration of conformity can be viewed at the manufacturer's site. 3.6 TSE symbols The TSE symbols document that the product has been checked by TSE and approved for sale in Turkey. 4 Installation 4. Unpacking the product. Remove the product from its box. 2. Remove the protective film from all parts of the product. 4.2 Checking the scope of delivery Check that the scope of delivery is complete. Quantity Description Heat generator Hanging bracket Air vent Installation template Bag with small parts: 2 bolts 2 rawl plugs 6 seals Guarantee card Service list Enclosed documentation 8 Installation and maintenance instructions _00

9 Installation Dimensions Dimensions Nitron Condense 24 (H- TR) Nitron Condense 28 (H- TR) A 405 mm 430 mm B 39 mm 4.5 mm C 64 mm 76.5 mm D mm 25 mm Minimum clearances A A 7 B B C Minimum clearance A B 200 mm 200 mm B 5 5 C C 300 mm D 4.5 Clearance from combustible components The clearance from the product, the flue pipe and the flue gas guiding to components made of combustible materials must be insulated using fireproof material Using the installation template Use the installation template to ascertain the locations at which you need to drill holes and make perforations. Heating flow (22 mm diameter) 2 Hot water connection (dia. 5 mm) 3 Gas connection (22 mm diameter) 4 Cold water connection (dia. 5 mm) 5 Heating return (22 diameter) 6 Filling device 7 Hanging bracket 8 Connection for flue gas guiding _00 Installation and maintenance instructions 9

10 4 Installation 4.7 Wall-mounting the product 4.8 Installing/removing the front casing and the chamber cover 4.8. Removing the front casing C. Check whether the wall has sufficient load-bearing capacity to bear the operational weight of the product. 2. Check if the supplied fixing material may be used for the wall. Conditions: The load-bearing capacity of the wall is sufficient, The fixing material may be used for the wall B 2x A Wall-mount the product as described. Conditions: The load-bearing capacity of the wall is not sufficient Ensure that wall-mounting apparatus on-site has a sufficient load-bearing capacity. Use individual stands or primary walling, for example. Do not wall-mount the product if you cannot provide wall-mounting apparatus with a sufficient load-bearing capacity. Remove the front casing as shown in the illustration Removing the chamber cover C Conditions: The fixing material may not be used for the wall Wall-mount the product as described using the permitted fixing material provided on-site. A 2x B Remove the front chamber cover, as shown in the illustration. 0 Installation and maintenance instructions _00

11 Installation Removing the combustion chamber cover Installing the front casing A 2x Remove the combustion chamber cover, as shown in the illustration Installing the combustion chamber cover C B Install the front casing as shown in the illustration. 4.9 Removing/installing the side section 4.9. Removing the side section. 2. Remove the front casing. ( Page 0) Remove the front chamber cover. ( Page 0) B Install the combustion chamber cover, as shown in the illustration. 2x Installing the chamber cover A A C Caution. Risk of material damage caused by mechanical deformation. C 2x Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for example, and potentially result in leaks. B Install the front chamber cover, as shown in the illustration _00 Installation and maintenance instructions 3. Always only remove one side section never both side sections at the same time. Remove the side section as shown in the illustration.

12 5 Installation Installing the side section B If, during gas leak-tightness tests, you have closed the gas isolator cock that is installed upstream of the product, relieve the gas line pressure before you open this gas isolator cock. Caution. Risk of damage caused by corrosion. If non-diffusion-tight plastic pipes are used in the heating installation, this may cause air to enter the heating water and corrosion of the heat generation circuit and the boiler. If using non-diffusion-tight plastic pipes in the heating installation, separate the system by installing an external heat exchanger between the boiler and the heating installation. A 2x C. Install the side section as shown in the illustration. 2. Install the front chamber cover. ( Page ) 3. Install the front casing. ( Page ) 5 Installation Danger! Risk of explosion or scalding caused by incorrect installation. Stresses in the supply line can cause leaks. Make sure there is no voltage in the supply lines when they are installed. Caution. Risk of material damage due to contaminated lines. Foreign bodies, such as welding remnants, sealing residues or dirt in the water pipes, may cause damage to the product. Flush the heating installation thoroughly prior to installation. Caution. Risk of material damage due to the gas leak-tightness test. At a test pressure of > kpa (0 mbar), gas leak-tightness tests may cause damage to the gas valve. If, during gas leak-tightness tests, you also place the gas lines and the gas valve in the product under pressure, use a max. test pressure of kpa (0 mbar). If you cannot limit the test pressure to kpa (0 mbar), close any gas isolator cocks that are installed upstream from the product before you carry out the gas leaktightness test. Caution. Risk of material damage due to heat transfer during soldering. Do not solder the connection pieces if the connection pieces are screwed to the service valves. 5. Installation requirements 5.. Information on liquid gas operation In the as-delivered condition, the product is preset for operation with the gas group indicated on the identification plate. If you have a product that has been preset for operation with natural gas, you must convert it to run on liquid gas. You will need a conversion kit for this. The conversion procedure is described in the manual supplied with the conversion kit Purging the liquid gas tank If the liquid gas tank is not purged properly, this may result in ignition problems. Ensure that the liquid gas tank has been purged properly before installing the product. If required, contact the filler or the liquid gas supplier Using the correct type of liquid gas Using the incorrect type of liquid gas may cause fault shutdowns in the product. Ignition and combustion noise may occur in the product. Only use the gases listed on the identification plate Basic preparation for the installation Install a stop cock on the gas line. Make sure that the existing gas meter is capable of passing the rate of gas supply required. Flush out the supply lines thoroughly prior to installation. Install a hot water safety group and a stop cock on the cold water pipe. Install a filling device between the cold water pipe and the heating flow. 2 Installation and maintenance instructions _00

13 Installation 5 Check whether the volume of the installed expansion vessel is sufficient for the heating system. Conditions: The volume of the installed expansion vessel is insufficient Install an additional expansion vessel, connected as close to the product as possible, in the heating return. Conditions: External expansion vessel installed Install a non-return valve in the product outlet (heating flow) or decommission the internal expansion vessel in order to prevent the warm start function from being increasingly activated due to backflow. Install a tundish with siphon for the condensate discharge and the exhaust pipe on the expansion relief valve. Lay as short a drain line as possible, at a downward gradient away from the tundish. Insulate bare pipes exposed to environmental influences to protect them from frost using suitable insulating material. 5.4 Filling the siphon and connecting the condensate discharge pipe Danger! Risk of death from escaping flue gases! The siphon's condensate drain pipework must not be connected to waste-water piping because, otherwise, the internal condensate siphon may be drained fully and flue gas may escape. Do not connect the condensate drain pipework tightly to the waste-water piping. 5.2 Installing the gas connection and heating flow/return D B 50 ml A C. Install the gas line on the gas connection (2) without tension. 2. Purge the gas line before start-up. 3. Install the heating flow (3) and the heating return () in accordance with the relevant standards. 4. Check all connections for leaks. 5.3 Installing the hot and cold water connection 2 3 Only use pipes which have been manufactured from acid-resistant material (e.g. plastic) for the condensate drain pipework. Leave an installation space of at least 240 mm beneath the condensate siphon. Loosen the lower section of the siphon () from the condensate siphon. Fill the lower section of the siphon with 50 ml water. Secure the condensate discharge pipe to the lower section of the siphon. Re-fit the lower section of the siphon onto the condensate siphon. Suspend the condensate discharge pipe above the preinstalled tundish. 5.5 Connecting the discharge pipe to the expansion relief valve on the product. Install the supplied discharge pipe for the expansion relief valve so that it does not interfere with the removal and fitting of the siphon trap. 2 Install the cold water connection (2) and hot water connection () in accordance with the relevant standards. 2. Install the discharge pipe () as shown _00 Installation and maintenance instructions 3

14 5 Installation 3. Terminate the line in such a way that escaping water or steam cannot cause injury to persons or damage to electronic components. 4. Make sure that the line end is visible. 5.6 Flue gas installation Danger! Risk of poisoning due to escaping flue gas. Mineral-oil-based greases can damage the seals. Instead of grease, use only water or commercially available soft soap to aid installation. Downward gradient to the inside: 5% 2. Install the air/flue pipe as described in the separate installation instructions for the air/flue pipe Air/flue gas installation Complying with the minimum clearances for the air/flue gas installation Comply with the minimum clearances for the air/flue gas installation. ( Page 35) Horizontal/vertical air/flue gas installation Applicability: B22 type flue pipe 5.6. Installing the connection piece for the flue pipe L2 L 2 In this configuration, an old flue gas duct can be used to create an outlet for an open-flued boiler/combination unit.. Position the connection piece () on the product. Conditions: Total length of the connection piece and air/flue pipe metre Also install the air throttle (2). Screw the connection piece in tightly Installing the air/flue pipe 5 % (~3 ) 50 mm / m In this configuration, the statutory regulations on air supply must be satisfied. The supply air is extracted from the room in which the unit is installed via the elbow of the horizontal flue pipe attachment. The horizontal length (L) is a simple pipe (dia. 80/80 mm). This length takes into account the loss of pressure through the elbow. For each additional 90 elbow (or two 45 elbows) that is required, the length (L) must be reduced by m (for 80/80 mm diameter). The length of the hearth (L2) must be taken into consideration and it must be proven that it works correctly. Length of the air/flue gas installation, dia. 80/80 mm ( Page 36). Ensure that there is a minimum downward gradient of 5% between the elbow and the terminal of the air/flue pipe so that condensate can flow back to the unit. 4 Installation and maintenance instructions _00

15 Installation Horizontal/vertical air/flue gas installation Applicability: B22P air/flue pipe Length of the air/flue gas installation, dia. 60/00 mm ( Page 36) Length of the air/flue gas installation, dia. 80/25 mm ( Page 36) Vertical air/flue gas system Applicability: C32 type flue pipe L2 L L In this configuration, a flue-gas or ventilation duct can be used to create an outlet for an open-flued boiler/combination unit. In this configuration, the statutory regulations on air supply must be satisfied. The supply air is extracted from the room in which the unit is installed via the elbow of the horizontal flue pipe attachment. The horizontal length (L) is a simple pipe (dia. 80/80 mm). This length takes into account the loss of pressure through the elbow. For each additional 90 elbow (or two 45 elbows) that is required, the length (L) must be reduced by m (for 80/80 mm diameter). The vertical length (L2) is a rigid flue gas pipe measuring 80 mm in diameter. Length of the air/flue gas installation, dia. 80/80 mm ( Page 36) For each additional 90 elbow (or two 45 elbows) that is required, the length (L) must be reduced by m (for 60/00 mm diameter or for 80/25 mm diameter). Length of the air/flue gas installation, dia. 60/00 mm ( Page 36) Length of the air/flue gas installation, dia. 80/25 mm ( Page 36) Air/flue gas installation for header lines Applicability: C42 type flue pipe Horizontal air/flue gas system Applicability: C2 type flue pipe L L For each additional 90 elbow (or two 45 elbows) that is required, the length (L) must be reduced by m (for 60/00 mm diameter or for 80/25 mm diameter). The connection from the product to the line in the chimney is established using the accessory that was specially developed by the product manufacturer _00 Installation and maintenance instructions 5

16 5 Installation A boiler/combination unit that is connected to a type C42 system must only be connected to natural draught chimneys. The condensate from header line systems must not drain into the boiler/combination unit. For each additional 90 elbow (or two 45 elbows) that is required, the length (L) must be reduced by m (for 80/80 mm diameter). Length of the air/flue gas installation, dia. 80/80 mm ( Page 36) Horizontal or vertical air/flue gas system with natural draught Applicability: C62 type flue pipe Air/flue gas system via separate pipes Applicability: C52 type flue pipe L L2 Each line that runs through a wall and whose temperature exceeds the room temperature by 60 C must be equipped with thermal insulation where it passes through the wall. This may be carried out using suitable insulating material with a strength of 0 mm and thermal conductivity of λ 0.04 W/mK (e.g. glass wool). The attachments for the fresh air supply and flue gas extraction must not be installed on opposite walls of the building. For each additional 90 elbow (or two 45 elbows) that is required, the length (L+L2) must be reduced by 2 m (for 80/80 mm diameter). Length of the air/flue gas installation, dia. 80/80 mm ( Page 36) The entire accessory that is used must at least correspond to a T temperature class of 200 C and comply with the requirements of standard EN 443. The maximum pressure loss in the lines must not be above 00 Pa. Length of the air/flue gas installation, dia. 60/00 mm ( Page 36) Length of the air/flue gas installation, dia. 80/80 mm ( Page 36) Length of the air/flue gas installation, dia. 80/25 mm ( Page 36) Air/flue gas system via separate pipes for single or header line Applicability: C82 type flue pipe L2 L The condensate from header line systems must not drain into the boiler/combination unit. 6 Installation and maintenance instructions _00

17 Installation 5 The flue gas connection is implemented via a branch connection on the single or header line in natural draught operation. The diameter of the line is to be determined depending on the total output of the connected units. For each additional 90 elbow (or two 45 elbows) that is required, the length (L+L2) must be reduced by 2 m (for 80/80 mm diameter). Length of the air/flue gas installation, dia. 80/80 mm ( Page 36) Closing the electronics box A 5.7 Electrical installation In Turkey, the electrical installation must only be carried out by authorised and qualified electricians. Danger! Risk of death from electric shock! The mains connection terminals L and N remain live even if the product is switched off. Switch off the power supply. Secure the power supply against being switched on again Opening/closing the electronics box Opening the electronics box. Remove the front casing. ( Page 0) A 4x B. Close the electronics box as shown in the illustration. 2. Install the front casing. ( Page ) Carrying out the wiring A Caution. Risk of material damage caused by incorrect installation. Mains voltage at the incorrect plug terminals on the product may destroy the electronics. Only connect the mains connection line to the terminals marked for the purpose.. Shorten the supply lines to the appropriate length. B B 2. Open the electronics box as shown in the illustration. 30 mm max. 2. Ensure that the outer sheathing on the flexible lines is correctly stripped in order to prevent short circuits if a strand becomes loose. Stripping: 30 mm 3. Ensure inner conductor insulation is not damaged when stripping the outer sheathing. 4. Only strip inner conductors just enough to establish stable connections. 5. To avoid short circuits resulting from loose individual wires, fit conductor end sleeves on the stripped ends of the conductors. 6. Screw the respective plug to the supply line. 7. Check whether all conductors are sitting mechanically securely in the terminals of the plug. 8. Plug the plug into the associated PCB slot. 9. Secure the cables in the electronics box using the strain reliefs _00 Installation and maintenance instructions 7

18 6 Operation Establishing the power supply. Ensure that the rated mains voltage is correct. Rated mains voltage: 230 V 2. Make sure that the product is earthed. 4. Tilt the electronics box upwards. 5. Install the front casing. ( Page ) 6. After start-up, check whether the parameter PP06 is set correctly in the parameter menu. ( Page 22) Installer level Overview ( Page 27) Connecting the outside temperature sensor. Remove the front casing. ( Page 0) 2. Tilt the electronics box downwards Connect the product using a fixed connection () and an electrical partition with a contact opening (2) (e.g. fuses or line protection switches). Contact opening on the partition: 3 mm Mains connection line: Flexible line 4. Carry out the wiring. ( Page 7) 5. Make sure that access to the mains connection is always available and is not covered or blocked. 5.8 Connecting additional components Danger! Risk of death from electric shock! The mains connection terminals L and N remain live even if the product is switched off. Switch off the power supply. Secure the power supply against being switched on again Connecting the room thermostat. Remove the front casing. ( Page 0) 2. Tilt the electronics box downwards. 3. Connect the cable for the outside temperature sensor to the corresponding terminal. 4. Tilt the electronics box upwards. 5. Install the front casing. ( Page ) 6. After start-up, set the heating curve. ( Page 23) 6 Operation 6. Operating concept The operating concept, the operation of the product and the read-off and setting options in the operator level are described in the operating instructions. An overview of the read-off and setting options of the installer level can be found in the "Installer level Overview" table in the appendix. Installer level Overview ( Page 27) 6.2 Calling up the installer level. Turn the rotary knob as far as it will go in an anticlockwise direction. 2. Press. Button push: 5 s The installer level is called up. 3. Use the rotary knob to enter the code for the installer level. Code: Confirm by pressing. 3. Connect the room thermostat cable to the corresponding terminal. 8 Installation and maintenance instructions _00

19 Start-up 7 7 Start-up 7. Initial start-up In Turkey, the initial start-up must only be carried out by an authorised person. 7.2 Switching on the product Turn the rotary knob to the right. The basic display appears on the display. 7.3 Checking and treating the heating water/filling and supplementary water Caution. Risk of material damage due to poor-quality heating water Ensure that the heating water is of sufficient quality. Before filling or topping up the system, check the quality of the heating water. Checking the quality of the heating water Remove a little water from the heating circuit. Check the appearance of the heating water. If you ascertain that it contains sedimentary materials, you must desludge the system. Use a magnetic rod to check whether it contains magnetite (iron oxide). If you ascertain that it contains magnetite, clean the system and apply suitable corrosion-protection measures, or fit a magnet filter. Check the ph value of the removed water at 25 C. If the value is below 8.2 or above 0.0, clean the system and treat the heating water. Ensure that oxygen cannot get into the heating water. ( Page 22) Checking the filling and supplementary water Before filling the system, measure the hardness of the filling and supplementary water. Treating the filling and supplementary water Observe all applicable national regulations and technical standards when treating the filling and supplementary water. Provided the national regulations and technical standards do not stipulate more stringent requirements, the following applies: You must treat the heating water in the following cases: If the entire filling and supplementary water quantity during the operating life of the system exceeds three times the nominal volume of the heating installation, or If the guideline values listed in the following table are not met, or If the ph value of the heating water is less than 8.2 or more than 0.0. Total heating output kw Water hardness at specific system volume ) 20 l/kw mg CaCO₃/ l mol/ m³ > 20 l/kw 50 l/kw mg CaCO₃/ l mol/ m³ > 50 l/kw mg CaCO₃/ l mol/ m³ < 50 < 300 < > to 200 > to 600 > ) Nominal capacity in litres/heating output; in the case of multiboiler systems, the smallest single heating output is to be used. Caution. Risk of material damage if the heating water is treated with unsuitable additives. Unsuitable additives may cause changes in the components, noises in heating mode and possibly subsequent damage. Do not use any unsuitable frost and corrosion protection agents, biocides or sealants. No incompatibility with our products has been detected to date with proper use of the following additives. When using additives, follow the manufacturer's instructions without exception. We accept no liability for the compatibility of any additive or its effectiveness in the rest of the heating system. Additives for cleaning measures (subsequent flushing required) Fernox F3 Sentinel X 300 Sentinel X 400 Additives intended to remain permanently in the system Fernox F Fernox F2 Sentinel X 00 Sentinel X 200 Additives for frost protection intended to remain permanently in the system Fernox Antifreeze Alphi Sentinel X 500 If you have used the above-mentioned additives, inform the operator about the measures that are required. Inform the operator about the measures required for frost protection _00 Installation and maintenance instructions 9

20 7 Start-up 7.4 Preventing low water pressure 7.7 Setting the heating flow temperature In order for the heating installation to operate properly, the display must show a filling pressure between 0. MPa and 0.2 MPa (.0 bar and 2.0 bar). If the heating installation extends over several storeys, higher filling pressures may be required to avoid air entering the heating installation. If the filling pressure falls below 0.03 MPa (0.3 bar), the product switches off. The display shows F0. Top up the heating water to start the product up again. 7.5 Filling and purging the heating installation Conditions: Heating mode (Winter mode) switched on 2. Ensure that the product is operating. 2. Flush the heating installation through. 3. Remove the front casing. ( Page 0) 4. Tilt the electronics box downwards. Press. Use the rotary knob (2) to set the required heating flow temperature. The set heating flow temperature is shown in the display (). 7.8 Setting the hot water temperature 2 5. Undo the cap on the automatic air vent (). Turning anti-clockwise: 5 6. Open the filling device valve so that the heating water flows into the heating installation. 7. Open all radiator valves and, if installed, services valves. 8. Purge the highest radiator until water flows out of the purging valve without bubbles. 9. Purge all other radiators until the entire heating installation has been completely filled with heating water. 0. Fill with heating water until the required filling pressure is reached.. Close the valve on the filling device. 2. Turn the cap on the automatic air vent to close it. Turning clockwise 3. Install the front casing. ( Page ) 4. Check all of the connections and the entire heating installation for leaks. 7.6 Filling and purging the hot water circuit. Open the cold water stop valve on the product and all the hot water draw-off valves. 2. Fill the hot water circuit until water escapes. The hot water circuit is filled and purged.. Press. Danger! Risk of death from Legionella. Legionella multiply at temperatures below 60 C. Ensure that the operator is familiar with all of the Anti-legionella measures in order to comply with the applicable regulations regarding legionella prevention. 2. Use the rotary knob (2) to set the hot water temperature. Conditions: Water hardness: > 3.57 mol/m³ Hot water temperature: 50 The set hot water temperature is shown in the display (). 3. Check all connections and the entire hot water circuit for leaks. 20 Installation and maintenance instructions _00

21 Start-up Checking and adjusting the gas ratio setting 7.9. Checking the factory-set gas ratio setting The product's combustion has been factory tested and is preset for operation with the gas group indicated on the identification plate. Check the information about the type of gas indicated on the identification plate and compare this with the type of gas available at the installation location. Conditions: The product design is not compatible with the local gas group Do not start up the product. If the gas was converted to liquid gas, you can find the correct values in the Technical Data. Conditions: The product design is compatible with the local gas group Proceed as described below Checking the gas connection pressure (gas flow pressure). Temporarily decommission the product. 2. Close the gas isolator cock. 3. Remove the front casing. ( Page 0) 4. Remove the valve cover. Permissible gas connection pressure for operation with G20 natural gas: 2 kpa (20 mbar) Permissible gas connection pressure for liquid gas operation G30: 3 kpa (30 mbar) Permissible gas connection pressure for liquid gas operation G3: 3.7 kpa (37.0 mbar) 0. Temporarily decommission the product.. Close the gas isolator cock. 2. Remove the pressure gauge. 3. Tighten the sealing screw on the measuring nipple. 4. Open the gas isolator cock. 5. Check the measuring nipple for gas tightness. Conditions: Gas connection pressure not in the permissible range Caution. Risk of material damage and operating faults caused by incorrect gas connection pressure. If the gas connection pressure lies outside the permissible range, this can cause operating faults in and damage to the product. Do not make any adjustments to the product. Do not start up the product. If you are unable to remedy the fault, contact the gas supply company. Close the gas isolator cock Checking the maximum heat load. Temporarily decommission the product. 2. Close the gas isolator cock. A A B 5. Use a screwdriver to undo the sealing screw on the measuring connection of the gas valve. 6. Connect a pressure gauge to the measuring nipple. 7. Start up the product. 8. Open the gas isolator cock. 9. Measure the gas connection pressure against atmospheric pressure. B 3. Loosen the sealing screw on the measuring nipple. 4. Connect a pressure gauge to the measuring nipple. Working materials: Pressure gauge _00 Installation and maintenance instructions 2

22 8 Adapting the unit to the heating installation 5. Start up the product. 6. Open the gas isolator cock. 7. Check the value on the pressure gauge. Technical data Gas adjustment values for the heat input ( Page 34) The value lies outside of the permitted range. Turn the brass screw () directly below the red ring and, at the same time, push the ball (3) within the red plastic screw (2) in order to set the correct value. 8. Temporarily decommission the product. 9. Close the gas isolator cock. 0. Tighten the sealing screw on the measuring nipple.. Open the gas isolator cock. 2. Check the measuring nipple for gas tightness Checking the minimum heat load. Temporarily decommission the product. 2. Close the gas isolator cock. 3. Secure the valve cover. 4. Open the gas isolator cock. 5. Check the measuring nipple for gas tightness. 6. Install the front casing. ( Page ) 7. Start up the product. 7.0 Checking function and leak-tightness Before you hand the product over to the operator: Check the gas line, the flue gas installation, the heating installation and the hot water pipes for leaks. Check that the air/flue pipe and condensate drain pipework have been installed correctly. Check that the front casing has been installed correctly Checking the heating mode. Make sure that there is a heat requirement. 2. Check that the radiator is becoming warm Checking the hot water generation. Open a hot water valve completely. 2. Check that the water is becoming warm. B A 3. Loosen the sealing screw on the measuring nipple. 4. Remove the cable from the modulation coil. 5. Connect a pressure gauge to the measuring nipple. Working materials: Pressure gauge 6. Start up the product. 7. Open the gas isolator cock. 8. Check the value on the pressure gauge. Technical data Gas adjustment values for the heat input ( Page 34) The value lies outside of the permitted range. Turn the red plastic screw () in order to set the correct value. 9. Temporarily decommission the product. 0. Close the gas isolator cock.. Tighten the sealing screw on the measuring nipple. 2. Secure the cable for the modulation coil. 8 Adapting the unit to the heating installation You can change the system parameters in the installer level. You can find an overview of all the system parameters in the "Installer level Overview" table in the appendix. Installer level Overview ( Page 27) 8. Calling up/setting parameters Calling up the parameter menu. Call up the installer level. ( Page 8) 2. Alternatives / 2 Use the rotary knob to enter the code for the programmable parameters or fault messages. Programmable parameters: Code Fault messages: Code Alternatives 2 / 2 Press for the Info parameters. Button push: 7 s 3. Confirm by pressing. Button push: 5 s 4. Use the rotary knob to select the required parameter from the parameter menu. 5. Confirm by pressing. Button push: 5 s 6. If required, use the rotary knob to set the required setting (if possible). 7. Confirm by pressing. 22 Installation and maintenance instructions _00

23 Handing the product over to the operator 9 Button push: 5 s Exiting the parameter menu Note If you do not press any button for 30 seconds, the display automatically switches to the basic display. 8. Press once to exit the parameter menu. 9. Press again to exit the installer level. 8.. Setting the heating curve. In the parameter menu, call up the parameter PP6. ( Page 22) B A A Flow rate [Q (m₃/h)] B Remaining feed head [m] Setting the pump output B Temporarily decommission the product. ( Page 26) 2. Remove the front casing. ( Page 0) 3. Tilt the electronics box downwards A 2. Set the corresponding value for a constant room temperature using the outside temperature (A) and heating flow temperature (B). Room temperature: 20 Adjustment range for the heating curve: 5 35 K 3. Exit the parameter menu and switch back to the basic display. ( Page 23) 8..2 Setting the offset value for Eco mode. In the parameter menu, call up the parameter PP2. ( Page 22) 2. Set the required offset value. "0" setting: 0 "" setting: 5 3. Exit the parameter menu and switch back to the basic display. ( Page 23) 8.2 Remaining feed head of the pump 4. Set the switch () on the heating pump to the required level depending on the heating installation. Default setting: Stage 2 Stage: 3 5. Tilt the electronics box upwards. 6. Open the gas isolator cock and, in combination products, the cold water stop valve. 7. Install the front casing. ( Page ) 8. Switch on the product. ( Page 9) 9 Handing the product over to the operator Explain to the operator how the safety devices work and where they are located. Inform the operator how to handle the product. In particular, draw attention to the safety information which the operator must follow. Inform the operator of the necessity to have the product maintained according to the specified intervals. Pass all of the instructions and documentation for the product to the operator for safe-keeping. Inform the operator about measures taken to ensure the supply of combustion air and flue gas guiding, and instruct the operator that he must not make any changes _00 Installation and maintenance instructions 23

24 0 Troubleshooting 0 Troubleshooting 0. Rectifying faults If fault messages (FXX) appear or malfunctions occur, rectify the fault or malfunction after carrying out the checks listed in the tables in the appendix. Fault messages Overview ( Page 29) Troubleshooting Overview ( Page 29) Press the fault clearance key (max. three times) to restart the product. If you are unable to rectify the fault and the fault recurs despite fault clearance attempts, contact Customer Service. 6. Insert the new burner. 7. Screw in the burner () tightly. 8. Insert the cable connection from the ignition and monitoring electrode (3) Replacing the heat exchanger Calling up/clearing the fault memory If faults have occurred, the last ten (max.) fault messages are available in the fault memory. Call up the installer level. ( Page 8) Call up the fault parameters. ( Page 22) Call up the individual fault messages using the rotary knob. Clear the fault messages by pressing. Button push: 7 s Exit the parameter menu. ( Page 23) 0.3 Preparing the repair work. Temporarily decommission the product. ( Page 26) 2. Disconnect the product from the power mains. 3. Remove the front casing. ( Page 0) 4. Remove the front chamber cover. ( Page 0) 5. Remove the combustion chamber cover. ( Page ) 6. Remove both side sections. ( Page ) 7. Close the service valves in the heating flow, in the heating return and in the cold water pipe. 8. Drain the product if you want to replace water-bearing components of the product. ( Page 25) 9. Make sure that water does not drip on live components (e.g. the electronics box). 0. Use only new seals Replacing the burner. Unscrew the screws on the gas distributor pipe (2). 2. Remove the cable connection from the ignition and monitoring electrode (3). 3. Pull out the burner () towards the front and out. 4. Remove the screws for the ignition and monitoring electrode (3) from the burner. 5. Screw the ignition and monitoring electrode (3) tightly onto the burner Undo the clamps (2) on the flow pipe and the return pipe (3). 2. Remove the upper flow pipe and return pipe (3). 3. Loosen the overheating thermostat () from the heat exchanger by pressing the clamp. 4. Pull the heat exchanger (4) towards the front and out. 5. Insert the new heat exchanger. 6. Replace all the seals. 7. Install the upper flow pipe and return pipe (3). 8. Secure the clamps (2) on the flow pipe and return pipe (3). 9. Secure the overheating thermostat () to the heat exchanger Replacing the expansion vessel. Drain the product. ( Page 25) 2. Remove the side section. ( Page ) 3. Loosen the expansion vessel's flexible hose from the heating pump by unclipping it from the heating pump. 4. Pull out the expansion vessel upwards. 5. Insert the new expansion vessel into the product. 6. Secure the expansion vessel's flexible hose to the heating pump by the clipping it into the heating pump. Use a new seal for this. 7. Fill and purge the product and, if required, the heating installation. ( Page 20) Replacing the PCB. Open the electronics box. ( Page 7) 2. Remove all of the plugs from the PCB. 3. Undo the clips on the PCB. 4. Remove the PCB. 5. Install the new PCB in such a way that it clicks into the bottom and top of the clip. 6. Secure the plugs. 7. Close the electronics box. ( Page 7) 24 Installation and maintenance instructions _00

25 Observing inspection and maintenance intervals 0.4 Completing repair work. Install the combustion chamber cover. ( Page ) 2. Install the side sections. ( Page 2) 3. Install the front chamber cover. ( Page ) 4. Install the front casing. ( Page ) 5. Establish the power supply. 6. Switch on the product. ( Page 9) 7. Open all service valves and the gas isolator cock. 8. Check that the product works correctly and is leak-tight. ( Page 22) 6. Clean the ribs of the heat exchanger to remove combustion residue. 7. Slide the heat exchanger back again. 8. Install the upper flow pipe and return pipe (3). 9. Secure the clamps (2) on the flow pipe and return pipe (3). 0. Secure the overheating thermostat () to the heat exchanger.. Install both side sections. ( Page 2).2.2 Cleaning the burner Observing inspection and maintenance intervals Adhere to the minimum inspection and maintenance intervals. The inspection may require maintenance to be carried out earlier, depending on the results. Inspection and maintenance work Overview ( Page 28). Procuring spare parts The original components of the product were also certified as part of the declaration of conformity. If you do not use certified Demir Döküm original spare parts for maintenance or repair work, this voids the conformity of the product. We therefore strongly recommend that you install Demir Döküm original spare parts. Information about available Demir Döküm original spare parts is available by contacting the contact address provided on the reverse of this document. If you require spare parts for maintenance or repair work, use only Demir Döküm original spare parts..2 Preparing the cleaning work Temporarily decommission ( Page 26) the product. Remove the front casing. ( Page 0) Remove the front chamber cover. ( Page 0) Remove the combustion chamber cover. ( Page ) Fold the electronics box down and protect the electronics box against sprayed water..2. Cleaning the heat exchanger. Remove both side sections. ( Page ) Undo the clamps (2) on the flow pipe and the return pipe (3). 3. Remove the upper flow pipe and return pipe (3). 4. Loosen the overheating thermostat () from the heat exchanger by pressing the clamp. 5. Pull the heat exchanger (4) towards the front and out. 2 3 Clean the burner to remove combustion residue..2.3 Cleaning the filter in the cold water inlet. Drain the product on the hot water side by undoing the screwed connections on the hot water pipe. 2. Remove the pipe, including the screwed connections, from the product. 3. Rinse the filter under a jet of water, holding it against the direction of flow. 4. Secure the pipe back in place. 5. Always use new seals and screw in all components again..3 Completing cleaning work Install the combustion chamber cover. ( Page ) Install the front chamber cover. ( Page ) Tilt the electronics box upwards. Install the front casing. ( Page ) Open the gas isolator cock and, in combination products, the cold water stop valve. Switch on the product. ( Page 9).4 Draining the product. Turn the rotary knob as far as it will go in an anticlockwise direction. 2. Close the service valves of the product. 3. Close the gas isolator cock. 4. Remove the front casing. ( Page 0) 5. Tilt the electronics box downwards. 6. Open the drain valve. 7. Ensure that the automatic air vent cap on the internal heating pump is open. 8. Remove the motor from the diverter valve. 9. Push the pin on the diverter valve to the mid-position until the product has been completely drained. 0. Secure the diverter valve motor.. Turn the automatic air vent cap on the internal heating pump to close it _00 Installation and maintenance instructions 25

26 2 Decommissioning 2. Close the drain valve. 3. Tilt the electronics box upwards. 4. Install the front casing. ( Page ).5 Checking the admission pressure of the expansion vessel. Close the service valves and drain the product. ( Page 25) 2. Measure the admission pressure of the expansion vessel at the vessel valve. Conditions: Pre-charge pressure < 0. MPa ± 0.02 MPa ( bar ± 0.2 bar) Top up the expansion vessel in accordance with the static height of the heating installation, ideally with nitrogen, otherwise with air. Ensure that the drain valve is open when topping up. 3. If water escapes from the valve of the expansion vessel, you must replace the expansion vessel. 4. Fill and purge the heating installation. ( Page 20).6 Completing inspection and maintenance work Check the gas connection pressure (gas flow pressure). ( Page 2) 2 Decommissioning 2. Temporarily decommissioning the product Turn the rotary knob as far as it will go in an anticlockwise direction. The display goes out. Close the gas isolator cock. In combination products, also close the cold water stop valve. 2.2 Decommissioning the product Turn the rotary knob as far as it will go in an anticlockwise direction. The display goes out. Disconnect the product from the power mains. Close the gas isolator cock. In combination products, also close the cold water stop valve. Drain the product. ( Page 25) 3 Recycling and disposal Disposing of the packaging Dispose of the packaging correctly. Observe all relevant regulations. 4 Customer service 24 saat Müşteri İletişim Merkezi: Internet: 26 Installation and maintenance instructions _00

27 Appendix Appendix A Installer level Overview Setting level Values Default Unit Increment, select, explanation Min. Max. setting Installer level Enter code (competent person code 96) Installer level Programmable parameters (code ) PP0 Gas type = Natural gas 0 = LPG PP02 Maximum load = 00% 0 = 90% 02 = 80% 03 = 70% PP04 Heating temperature range = C (radiator heating) 0 = C (underfloor heating) PP06 Room thermostat = Room thermostat not installed 0 = Room thermostat installed PP08 Transition between hot water generation/heating = Immediate transition from hot water generation to heating 0 = Transition from hot water generation to heating after 45 s PP Ignition capacity selection = Automatic ignition = 0.3 x L max. 02 = 0.4 x L max. 03 = 0.5 x L max. 04 = 0.6 x L max. PP2 Offset value (Eco mode) = 0 C 0 0 = 5 C PP3 hot water handling mode = Outflow 7 C 0 0 = Return, set value +7 C; flow set value +6 C PP5 AFTC waiting period (Comfort = No waiting period 03 mode) 0 = minute 02 = 2 minutes 03 = 3 minutes 04 = 4 minutes 05 = 5 minutes PP6 Outside temperature exponent K 5 20 (heating curve) PP7 Timer programming logic = Active logic value = Active logic value PP8 Pump speed (for high-efficiency Depending on the pump. 00 pump only) Installer level Info parameters IF = Fault = Flow temperature IF = Fault = Hot water temperature IF03 l/min 0 = No flow rate (DHW) present Current value = Flow rate (DHW) IF04 Software IF05 Gas valve (modulation) ¹ If fault messages are present, the last ten fault messages are saved and the latest fault message is displayed _00 Installation and maintenance instructions 27

28 Appendix Setting level Min. Values Max. Unit Increment, select, explanation Default setting IF = Fault = Return temperature IF = No outside temperature sensor connected = Outside temperature sensor IF = No collector temperature = Collector temperature Installer level Fault messages (code 26) FXX ¹ If fault messages are present, the last ten fault messages are saved and the latest fault message is displayed. B Inspection and maintenance work Overview The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If national regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed in the table. No. Work Inspection (annual) Maintenance (at least every 2 years) Check the flue pipe for leak-tightness and correct fastening. Make sure that it is not blocked or damaged and has been installed in accordance with the relevant Installation Manual. X X 2 Check the general condition of the product. Remove dirt from the product and from the vacuum chamber. X X 3 Visually inspect the general condition of the entire heating cell and, in particular, check for signs of corrosion, soot or other damage. If you notice any damage, carry out maintenance work. X X 4 Check the gas connection pressure at maximum heat input. If the gas connection pressure is not within the correct range, carry out maintenance work. X X 5 Disconnect the product from the power mains. Check that the electrical plug connections and other connections are seated correctly and correct their position if necessary. X X 6 Close the gas isolator cock and the service valves. X X 7 Drain the product on the water side (observe the pressure gauge). Check the admission pressure of the expansion vessel and top the vessel up if necessary (approx MPa/0.3 bar below X the system filling pressure). 8 Clean the heat exchanger. X 9 Check the burner for damage and replace the burner if necessary. X 0 If the volume of water is insufficient or the outlet temperature is not reached, replace the secondary heat exchanger if necessary (only for products with hot water generation). X Clean the filter in the cold water inlet. Replace the filter if impurities can no longer be removed or if the filter is damaged. If this is the case, check the impeller sensor for dirt and damage too; X clean the sensor (do not use compressed air) and replace the sensor if it is damaged. 2 Open the gas isolator cock, reconnect the product to the power mains and switch the product on. X X 3 Open the service valves, fill up the product/heating installation to MPa/ bar (depending on the static height of the heating installation) and purge the system. X 4 Perform a test operation of the product and heating installation, including hot water generation (if available), and purge the system once more if necessary. X X 5 Visually inspect the ignition and burner behaviour. X X 6 Check the product for gas, flue gas and hot water leaks, and repair the leaks if necessary. X X 7 Record the inspection/maintenance work carried out. X X 28 Installation and maintenance instructions _00

29 Appendix C Fault messages Overview Fault code Meaning Possible cause F0 Overheating The safety cut-out or the overheating thermostat interrupts circulation. (RE- SET) The flue gas temperature sensor in the recuperator is defective. F02 NTC fault (hot water) The hot water temperature is outside of the permitted range. F03 NTC fault (flow) The cable connections are defective/faulty. F04 Ignition fault The gas ratio settings are incorrect. (RESET) F05 Pressure cartridge defective The air circulation cuts out for 25 seconds. F06 NTC fault (return) The cable connections are defective/faulty. F07 Gas valve defective Control fault (RESET) F08 NTC sensor (return) overheated The return temperature is too high. F09 Pressure cartridge defective If the pressure cartridge is closed for 5 seconds (not operating), the fan then stops (a fault message is generated). If the pressure cartridge is open again (operating), normal operating mode automatically starts again. F0 System pressure incorrect Heating pump blocked, insufficient heating pump output, air in product, flow and return NTC connected the wrong way round. F Hot water temperature amplitude too high (heating mode) Heating pump blocked, insufficient heating pump output, air in product, system pressure too low, non-return valve blocked/incorrectly installed. F2 Mains voltage too low Break in plug connection for optional flue gas safety temperature limiter (safety cut-out), break in cable harness. F3 NTC sensors connected incorrectly or not connected Gas valve stepper motor not connected, multiple plug on the PCB not plugged in correctly, interruption in cable harness, gas valve stepper motor defective, electronics defective. F4 Ignition blocked The ignition signal was 5 seconds outside of the predefined time period. (RESET) F5 Flame failed, ignition blocked If the flame fails for 0 seconds, ignition is then blocked. (RESET) D Troubleshooting Overview Fault Cause Measure The product is not working or will not ignite, or the standby symbol is shown on the display. The heating pump and/or fan is not working. The power supply to the product has been interrupted. The voltage is lower than 80 V. The system pressure is too low. Check the power-supply connection and the fuses. Use a controller. Check the system pressure and fill with water, if necessary. The pressure sensor is defective. Measure the resistance between the connectors and replace if the sensor, if necessary. The overheating thermostat is defective. Replace the overheating thermostat. The PCB is defective. Replace the PCB. The water flow sensor is defective. Replace the sensor. The water pressure is too low when there is a hot water demand. Check the particle filter for dirt. The heating pump and/or fan is working. The fan or its corresponding cable is defective. Check whether the power supply to the fan is working and replace any defective components, if necessary. The air pressure sensor is defective. Replace the air pressure sensor and check the power-supply connections. The hose for the air pressure sensor has become disconnected. Reconnect the hose or replace it, if necessary. The connections to the ignition electrode are broken. Correct the connections _00 Installation and maintenance instructions 29

30 Appendix Fault Cause Measure The product is not working, no fault messages are flashing. The ignition electrode will not ignite, the burner is off. The product is not working, no faults have been reported and the display is off. The hot water supply is insufficient The hot water is not being heated. The product ends the heating circuit too quickly. The fuel is not reaching the product or the gas flow pressure is too low. The monitoring electrode is positioned incorrectly. The connection to be PCB is broken. The cable connection to the gas valve is broken. Although the gas flow pressure is sufficient, the gas acceleration to the product is insufficient. The cable connection to the monitoring electrode or the monitoring electrode is broken. The hot water level is too low. The heating pump is damaged. The PCB is defective. The fuse on the PCB is defective. The cable connections are defective. The water level is too high. The gas pressure is insufficient. Scale in the primary or secondary heat exchanger. The diverter valve or the cam from the hydraulic block is defective. The flow rate sensor (DHW) is defective or there is a fault in the hydraulic-block turbine. The temperature sensors are defective or deposits have built up on the contact surface. The hot water level is too low. The water pressure is insufficient. The diverter valve or the cam from the hydraulic block is defective. The flow rate sensor (DHW) is defective or there is a fault in the hydraulic-block turbine. The temperature sensors are defective or deposits have built up on the contact surface. Air in the heating installation. The heating installation is blocked by dirt. The heating pump is defective. Check the gas flow pressure and the fuel supply. Check the position of the monitoring electrode and the gas flow pressure. Check the cable connection to the PCB and replace the cable connection, if necessary. Check the cable connection to the gas valve and replace the cable connection, if necessary. Check the gas line. Check whether the cable connection/monitoring electrode is defective. If required, replace the defective component. Check the particle filter for dirt. Check whether the heating pump is working correctly. Check the particle filter for dirt. Check the PCB and replace it, if necessary. Replace the fuse. Replace the cable connections. Check the water level reducer. Check the cable connections to the gas inlet and to the modulation coil. Descale or replace the heat exchanger affected. Check whether the hot water supply is being heated. Check the flow rate sensor (DHW) and replace it, if necessary. Check the turbine for dirt. Check the temperature sensor. Check whether the product is drawing off a sufficient quantity of water when heating mode is off. Check the flow rate sensor (DHW) and the water pressure. Check the heating system during the drawoff process. Check the flow rate sensor (DHW) and replace it, if necessary. Check the turbine for dirt. Check the temperature sensor. Purge the heating installation. Check whether the discharge valve is blocked. Open the discharge valve slightly. Check the heating installation for dirt and clean it, if necessary. Replace the heating pump. 30 Installation and maintenance instructions _00

31 Appendix Fault Cause Measure The product ends the heating circuit too quickly. The expansion relief valve is leaking. There is a low level of heat loss. The system pressure is over 0.03 MPa (3 bar). Reduced air in the expansion vessel or a tear in the diaphragm. The expansion relief valve is defective. The volume of the heating water is more than 50 litres. The pressure sensor is defective. Reduce the gas valve pressure or reduce the system-capacity potentiometer in line with the heat loss. Reduce the system pressure. Check the expansion vessel and rectify the fault. Replace the expansion relief valve. Install an additional expansion vessel. Replace the pressure gauge _00 Installation and maintenance instructions 3

32 Appendix E Connection diagram X X9 aa bb ee ff 3 X8 cc dd 4 X7 xx yy zz xx yy zz X8 X9 X7 X3 X V 9 230V~ X X X X4 X N L N L 24 PCB for the product 2 Rev counter in the fan 3 Pump (PWM) 4 Collector temperature sensor 5 Timer (optional) 6 Room thermostat/earth connection/24 V 7 Return temperature sensor 8 Hot water temperature sensor 9 Flow temperature sensor 0 Flow rate sensor (DHW) 32 Installation and maintenance instructions _00

33 Appendix Overheating thermostat + flue gas temperature sensor 2 Earthing for the ignition electrode 3 Overheating thermostat 4 Air pressure sensor 5 Air pressure sensor 6 Water pressure switch 7 Gas valve 8 Ignition electrode 9 Monitoring electrode 20 Diverter valve 2 Heating pump 22 Fan 23 Gas valve 24 Power supply F Technical data Technical data General Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Heat output (min./max.) kw kw Heat input (min./max.) 3 25 kw 3 28 kw Permissible gas categories II 2H3+ II 2H3+ Gas connection, boiler side 5 mm 5 mm Flow/return heating connections, boiler side 22 mm 22 mm Hot and cold water connection, boiler side G 3/4 inch G 3/4 inch Expansion relief valve connector (min.) 5 mm 5 mm Air/flue gas connection (concentric) 60/00 mm 60/00 mm Air/flue gas connection (separated) 80/80 mm 80/80 mm Air/flue gas connection (concentric) 80/25 mm 80/25 mm G20 natural gas flow pressure 2 kpa (20 mbar) 2 kpa (20 mbar) G30 liquid gas flow pressure kpa ( mbar) kpa ( mbar) G3 liquid gas flow pressure 3.7 kpa (37.0 mbar) 3.7 kpa (37.0 mbar) Gas consumption m³/h m³/h Approved flue gas connections B22, B22P, C2, C32, C42, C52, C82,C62 Nominal efficiency (full load) 96.3 % 96. % Nominal efficiency (partial load, 30%) 99.7 % 99.7 % Nominal efficiency (partial load, 50-30%) 03 % 03 % NOx class 2 2 Boiler dimension, width 405 mm 430 mm Boiler dimension, height 720 mm 720 mm Boiler dimension, depth 330 mm 330 mm Net weight 37 kg 38 kg Flue gas temperature (at nominal heat loading of 80/60 C) Flue gas temperature (at nominal heat loading of 50/30 C) 5 5 CO content (at nominal heat loading of 80/60 C) 6 ppm 24 ppm CO 2 content (at nominal heat loading of 80/60 C) 8. % 8. % Technical data Heating B22, B22P, C2, C32, C42, C52, C82,C62 Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Maximum flow temperature Max. flow temperature adjustment range Water pressure MPa ( bar) MPa ( bar) Max. water volume (at 75 C) 40 l 40 l Expansion vessel (volume) 7l 7l _00 Installation and maintenance instructions 33

34 Appendix Technical data Electrics Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Electric connection 230 V/50 Hz 230 V/50 Hz Built-in fuse (slow-blow) 2 A 2 A Max. electrical power consumption 0 W ± 0% 40 W ± 0% Level of protection IP X4 D IP X4 D Test symbol/registration no. CE 0476CQ0908 CE 0476CQ0908 Technical data Hot water handling mode Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Lowest water volume 2.5 l/min 2.5 l/min Water volume (at ΔT = 30 K) 2 l/min 2 l/min Water pressure MPa ( bar) MPa ( bar) Hot water output temperature range Flue gas temperature (in hot water handling mode) Technical data Gas adjustment values for the heat input Natural gas H G20 (min./max.) G30 liquid gas (min./max.) G3 liquid gas (min./max.) Technical data Burner jets Nitron Condense 24 (H-TR) kpa ( mbar) kpa ( mbar) kpa ( mbar) Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) kpa ( mbar) kpa ( mbar) kpa ( mbar) Nitron Condense 28 (H-TR) Natural gas H (G20) diameter.20 mm.5 mm Liquid gas (G30/G3) diameter 0.72 mm 0.72 mm 34 Installation and maintenance instructions _00

35 Appendix G Air/flue gas installation G. Minimum clearances for the air/flue gas installation P Q Q Q R S T I Q D, E Q F J L G B A I C H O H M N M N K Installation site A Directly below an opening, air bricks, opening windows, etc., that can be opened. 300 mm B Above an opening, air bricks, opening windows, etc., that can be opened. 300 mm Minimum dimensions C Horizontally to an opening, air bricks, opening windows, etc., that can be opened. 300 mm D Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater pipes 75 mm E Below eaves 200 mm F Below balconies or car port roofs 200 mm G From vertical wastewater pipes or down pipes 50 mm H From external or internal corners 200 mm I Above floors, roofs or balconies 300 mm J From a surface facing a terminal 600 mm K From a terminal facing a terminal 200 mm L From an opening in the car port (e.g. door, window) which leads into the dwelling 200 mm M Vertical from a terminal on the same wall 500 mm N Horizontal from a terminal on the same wall 300 mm O From the wall on which the terminal has been installed 0 mm P From a vertical structure on the roof N/A Q Above the roof area 300 mm R Horizontal from adjacent windows on pitched or flat roofs 600 mm S Above adjacent windows on pitched or flat roofs 600 mm T Below adjacent windows on pitched or flat roofs 2000 mm _00 Installation and maintenance instructions 35

36 Appendix G.2 Length of the air/flue gas installation, dia. 60/00 mm Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Diameter of the flue pipe Dia. 60/00 (L) B22 type flue pipe B22P air/flue pipe C2 type flue pipe C32 type flue pipe C42 type flue pipe 3m 3m 3m 3m Diameter of the flue pipe Dia. 60/00 (L) C52 type flue pipe C62 type flue pipe C82 type flue pipe 3m 3m G.3 Length of the air/flue gas installation, dia. 80/80 mm Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Diameter of the flue pipe 80/80 (L) diameter B22 type flue pipe B22P air/flue pipe C2 type flue pipe C32 type flue pipe C42 type flue pipe 20 m 20 m 20 m 20 m 20 m 20 m Diameter of the flue pipe 80/80 (L) diameter C52 type flue pipe C62 type flue pipe C82 type flue pipe 20 m 20 m 20 m 20 m 20 m 20 m G.4 Length of the air/flue gas installation, dia. 80/25 mm Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Nitron Condense 24 (H-TR) Nitron Condense 28 (H-TR) Diameter of the flue pipe Dia. 80/25 (L) B22 type flue pipe B22P air/flue pipe C2 type flue pipe C32 type flue pipe C42 type flue pipe 7m 7m 7m 7m Diameter of the flue pipe Dia. 80/25 (L) C52 type flue pipe C62 type flue pipe C82 type flue pipe 7m 7m 36 Installation and maintenance instructions _00

37 Appendix G Air/flue gas installation Condesate Trap For Flue Pipe Using condensate adaptor is recommended for preventing to condensate. Vertical Condesate Trap Horizontal Condesate Trap 2 Condesate trap could be installed on vertical or horizontal position to flue pipe system. Vertical one is installed directly on boiler, horizontal one is installed after elbow or added flue pipe that shown on figure above. Threaded side of condensate hose must be connect with condensate trap, other side side must be mounted to syphon that shown above. Recommendation: Condensate traps usage is recommended for m. or longer flue pipes (flue pipe length > m) _00 Installation and maintenance instructions 37

38 Appendix Condensate Trap Kit Vertical condensate trap 2 Horizontal condensate trap 3 Syphon 4 Condensate hose 5 Clamp 6 T - elbow Danger! Siphon should be filled with water before condensate trap installation.make sure no flue leakage on connections of condensate hose both trap side and syphon side Installation and maintenance instructions _00

39 Index Index A Air/Flue pipe... 4 Installing... 4 Air/flue pipe, installed... 4 Applicability, instructions... 7 C Calling up parameters Calling up the fault memory Calling up the installer level... 8 Calling up the parameter menu CE label... 8 Channel vent, minimum clearances... 6 Checking the gas setting... 2 Checking the heat load Checking the heating mode Checking the pre-charge pressure of the expansion vessel Cleaning the burner Cleaning the filter Cleaning the heat exchanger Closing the electronics box... 7 Cold water connection... 3 Combustion air... 5 Completing inspection work Completing maintenance work Completing repair work Completing, repair work Condensate drain pipework... 3 Condensate siphon... 3 Connecting the outside temperature sensor... 8 Connecting the room thermostat... 8 Corrosion D Decommissioning Decommissioning, temporarily Deleting the fault memory Discharge pipe, expansion relief valve... 3 Disposal, packaging Disposing of the packaging Documents... 7 Draining the product E Eco mode, offset Electrical installation... 7 Electricity... 4 Exiting the parameter menu F Fault codes Fault messages Filling the heating installation Filling the hot water circuit Floor-standing oil-fired boiler... 6 Flue gas route Flue pipe equipment connection piece... 4 Front casing, closed... 4 Frost... 5 G Grease... 5 H Handing over to the operator Heat load, maximum... 2 Heat load, minimum Hot water connection... 3 I Ice formation... 5 If you smell gas... 3 Inspection work... 25, 28 Installation... 2 Installation site Installing the chamber cover... Installing the combustion chamber cover... Installing the front casing... Installing the gas connection... 3 Installing the heating flow... 3 Installing the heating return... 3 Installing the side section... 2 Intended use... 3 Isolator devices L Lightning... 6 Liquid gas... 4, 2 M Mains connection... 8 Maintenance work... 25, 28 Minimum clearance... 9 Minimum clearances, air/flue gas installation... 4 O Opening... 5 Opening the electronics box... 7 Operating concept... 8 P Power supply... 8 Preparing the repair work Preparing, repair work Pump, remaining feed head Purging the heating installation Purging the hot water circuit R Regulations... 6 Remaining feed head, pump Removing the chamber cover... 0 Removing the combustion chamber cover... Removing the front casing... 0 Removing the side section... Replacing the burner Replacing the expansion vessel Replacing the heat exchanger Replacing the PCB Replacing, expansion vessel S Safety device... 4 Schematic drawing... 4 Seal... 5 Setting parameters Setting the heating curve Setting the heating flow temperature Setting the hot water temperature Setting the offset value Setting the pump Solid fuel boiler... 6 Sooting... 6 Spare parts _00 Installation and maintenance instructions 39 37

40 Index Supply of combustion air... 4, 6 Switching off Switching off the product Switching on the product... 9 T Tool... 5 Transport... 5 Treating the heating water... 9 U Unpacking the product... 8 Use, intended... 3 V Voltage... 4 W Weight... 0 Wiring Installation and maintenance instructions _00

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44 Publisher/manufacturer TÜRK DEMIRDÖKÜM FABRIKALARI A.S. Ismet Inonu Cad. No: / Bozuyuk Bilecik DemirDöküm Genel Müdürlük _ :9:20 Bahçeli Evler Mahalle Bosna Bulvarı No: 48 Çengelköy İSTANBUL Tel: supplier Demir Döküm Genel Müdürlük Bahçelievler Mah. Bosna Bulvarı No: / Çengelköy İSTANBUL Tel Faks saat Müşteri İletişim Merkezi These instructions, or parts thereof, are protected by copyright and may be reproduced or distributed only with the manufacturer's written consent.